S and method for measuring strand

ABSTRACT

Wire strand is fabricated and subsequently severed into measured lengths of strand at locations determined on a wire of the strand during fabrication by passing the wire between rearwardly urged tension rolls, around a measuring wheel, and between unidirectional tension rolls.

United States Patent Inventor Charles R. Nippert, Sr.

Allentown, Pa.

Filed Sept. 19, 1967 Patented Jan. 19, 1971 Assignee Bethlehem SteelCorporation a corporation of Delaware APPARATUS AND METHOD FOR MEASURINGSTRAND 8 Claims, 3 Drawing Figs.

US. Cl 140/1, 29/417, 73/160, 226/109 Int. Cl B211 11/00 Field of Search140/1,'140,

[56] References Cited UNITED STATES PATENTS 757,810 4/1904 Hudson 33/1341,169,130 1/1916 Curtis..... 33/134 1,493,855 5/1924 Garnett 33/1342,929,136 3/1960 Andren 29/417 2,947,652 8/1960 Burr 140/ 1 PrimaryExaminer-Lowell A. Larson Attorney-Joseph J. OKeefe ABSTRACT: Wirestrand is fabricated and subsequently severed into measured lengths ofstrand at locations determined on a wire of the strand duringfabrication bypassing the wire between rearwardly urged tension rolls,around a measuring wheel, and between unidirectional tensionrolls.

PATENIEU JAN 1 9m fil a R Q. m b M APPARATUS AND METHOD FOR MEASURINGSTRAND CROSS-REFERENCES TO RELATED APPLICATIONS The measuring method anddevice of the instant invention is particularly suitable for, but notlimited to, use with the method and apparatus for making parallel wirestrand shown and described in application for Us. Letters Pat. Ser. No.575,038 filed Aug. 25. 1966 by J.L. Durkee et al.

BACKGROUND OF THE INVENTION This invention pertains to the measurementof wire. and strand into which the wire is fabricated, with a very highaccuracy.

It has in the past been a problem to obtain highly accurate measurementof wire with the measuringdevices available. A number of variations ofthese devices have been made based upon counting by suitable countingmechanisms of the revolutions of two rolls between which the wire ispassed. These devices have not proved highly accurate, largely, it isbelieved, because of slippage of the wires. The slippage problem hasbeen alleviated in some cases by passing the wire completely around theperiphery of a measuring wheel in order to obtain more frictionalsurface contact but the accuracy of such devices has still left much tobe desired.

In the past it has also been the custom to measure a strand directly bymeans of devices much like those used in measuring wire. During thestrandingof twisted cable, for instance, the length of cable fabricatedis customarily determined by a counting device connected to the drawingcapstan. Such an arrangement is unsatisfactory when accurate lengths ofstrand are to be fabricated particularly in the fabrication of parallelwire strand as described in the above noted applicationof Durkee et al.Where the finished strand must be accurate within very narrow tolerancesif it is to hang correctly between bridge towers and the like. It hasbeen necessary in such cases to resort to direct measurement of thefinished strand with a tape or similar means due to the inaccuracy ofpreviously available continuous measuring devices and also because thebinding on the outside of the finished parallel wire strand precludes anaccurate measurement of length by roller contact along the surface ofthe strand. In order to obtain an accurate mean measurement, however,the strand must be placed under a minimum tension while the measurementis being made, the required tension often approaching several thousandpounds and requiring special apparatus for its application.

SUMMARY OF THE INVENTION This invention provides an improved apparatusand method for measuring wire and strand by passing the wire about ameasuring wheel arranged in combination with a constant tensionrearwardly urged pair of tension rolls between which the wire initiallypasses, and a second pair of unidirectional ten sion rolls between whichthe wire passes after it leaves the BRIEF DESCRIPTION OF THE DRAWINGSFIG. 1 showsa plan view of a strandproducing-apparatus embodying thepresent invention.

FIG. 2 shows an elevation of the measuring device of the presentinvention.

FIG. 3 is an endelevati0n along 3-3 of FIG. 2.

DESCRIPTION OF THE PREFERRED EMBODIMENT FIG. I shows a layout of thefabrication of parallel wire strand. A plurality of swifts 11 and 13 arearranged to direct a series of wires 19 through a series of guides 23and 25 to lay plates 27, 29, 31 and 32 which direct the wires to aseries of rollercompacting dies 33. 47. 49, 50 and 51 between which theresulting parallel wire strand 41 is wrapped at intervals with asuitable tape of or other binding means to holdthe wires of the parallelwire strand together. A suitable pulling device 53, here shown as acatapuller--type capstan, pulls the wires 19 from the swifts 11 and 13through the lay plates 27, 29, 31 and 32 and compacting dies 33, 47 49.50 and 51 and passes the finished strand 41 along a roller conveyor 163and through traverse 161 to reeling device 157 where it is reeled on areel 159. One of the swifts 11 designated as 11a is dis placed slightlyto the side to allow the measuring device 61 of the present invention tobe positioned. along the path of the wire 19a from swift 11a to layplate 27. Swifts 11 and 13 will include braking devices, not shown.designed to place a back tension of approximately 25 to 30 pounds on thewires 19.

Measuring device 61 shown in detail in FIGS. 2 and 3 comprises a base63, comprising longitudinal members 64 and transverse members 66, uponwhich are mounted vertical support members 65 for large measuring wheel67 approximately six feet in diameter mounted on a shaft 69 rotatablyjournaled in bearings 71 mounted on support members 65. Braces 73 aid inrigidly tying support members 65 to base 63. Hinged members 75 pivotedon brackets 76 serve as adjustable mountings for pressure rolls 77 whichare urged against the bottom of a flat bottomed V-groove 79 in theperiphery of measuring wheel 67 by the action of spring 78 andcompression adjustment 80. A gear 81 is secured to shaft 69 and isoperatively connected by a chain 83 to a small gear 85 attached to theshaft of a mechanical counter mechanism 87 mounted on a bracket 89.

A pair of tension rollers 91 and 93 are mounted on shafts 9S and 97journaled in bearings 99 and 100 mounted on supporting structure 101 atthe left end of base 63 as viewed in FIG. 2. Tension roller 93 has ashallow groove: 103 in the periphery. Bearings 99 are slidably mountedin slideways 105 mounted on supporting structure 101 so that roll 91 maybe urged against the periphery of roll 93 by the action of springs 107the compression of which may be adjusted by screws 109. Shaft 97 isconnected by coupling 111 to the output shaft 113 of gear reducer 115the input shaft 117 of which is connected by coupling 119 to the shaftof an eddy current motor 121 or other motor of a design which may remainstationary or be rotated in a reverse direction without damage.

On the right side of base 63 there is mounted a support assembly 123with tension rolls 125 and 127 journaled therein in the same operativearrangement as is used to journal tension rolls 91 and 93 in supportingstructure 101. Tension roll 125 is slidably mounted to bear against theshallow grooved periphery of tension roll 127 the shaft of which .isprovidetd with a one-way clutch mechanism 131 of any. suitable designsuch as a cam clutch or roller clutch which .will operate. to preventrotation of roll 127 in a direction otherthan forward.

A zero index 133 is mounted upon two supports 135 adjacent to the pathof the wire from tension rollers 91 and 93 to the periphery of measuringwheel 67. A vernier index 137 is mounted on brace 73 adjacent to theperiphery of measuring wheel'67. The periphery of measuring wheel.67. ismarked off in intervals of degrees. A wire guide 13'9havingguiderollers141 is mounted on base 63 in front of tension rolls 91 and .93 to directthe wire between the rolls.

In operation of the measuring device a .wire 19a is threaded through therollers 141 of guide 139 from swift 11a and between tension rolls 91 and93, across the face of zero index 133, about the periphery of measuringwheel .67 for one turn and then between the tension rollers 125 and 127to a primary pulling apparatus such as catapuller 53 shown in FIG. 1.After the wire has been threaded between tension rolls 125 and 127 sothat it cannot be pulled back due to the one-way clutch mechanism 131,eddy current motor 121 is activated to place a constant rearward tensionupon the wireof approximately 25pounds or the like depending upon thewire characteristics.

A mark is placed on the wire adjacent to the zero index and the counter,which may preferably be a simple revolution counter, is set at zero andthe degree mark adjacent to a given index point on the vernier index isnoted. The measuring wheel will previously have been calibrated for theparticular gage wire which is to be measured so that it is known howmuch wire is passed through the device by one revolution of themeasuring wheel. The wires 19, including the wire 190 which is pulledagainst the back tension of eddy current motor 121, are then pulledthrough the apparatus until counter 87 indicates that the desired lengthof wire has passed the measuring wheel as determined by the requirednumber of revolutions of the measuring wheel 67 plus the number of extradegrees and parts of degrees of revolution over the required number ofcomplete revolutions read opposite the primary vernier mark on the wheeland on the vernier scale respectively. Preferably the gear ratio betweengear 81 and small gear 85 on the counter is sufficiently great so thatone revolution of the measuring wheel 67 will result in a number ofrevolutions of the counter. The reading on the counter is checked by thevernier indicator. The actual length of wire passing around themeasuring wheel during each revolution depends upon the gage of wirebeing measured as well as the circumference of the measuring wheel. Thewheel may be conveniently calibrated by actually measuring apredetermined length of wire with the measuring apparatus. With carefulcalibration it has been possible to obtain consistent wire measurementswith less than one inch of error in lengths of wire of over 4000 feetthat is less than .002 percent error-with little difficulty.

When used to measure a wire strand the measuring apparatus 61 of thepresent invention is placed between the swift from which one of thewires is taken as shown in FIG. 1 and the wire compacting die 33. In aparallel wire strand having a regular geometrical section such asdescribed in the above mentioned Durkee et al. application the wire tobe measured is preferably one of the outside corner wires of thegeometrical section. The measured wire is pulled with all the remainingwires by the pulling device 53 through the various lay plates and thecompacting dies 33, 47, 49, 50 and 51 and together with the other wiresis bound at intervals either by hand or by suitable mechanical bindingmeans between the various compacting dies as the strand is pulledforward. The strand is passed onto a reel 159 afterpassing through thepulling device 53. It will bee understood that in some applications thereeling device 157 might itself constitute the primary pulling device.

Upon first starting the strand-fabricating operation, after the variouswires 19 are entered into all the various apparatus wire 19a ispreferably painted with yellow quick drying paint in the area of thezero index 133. A thin pencil or other suitable mark is then made on thepainted area at the zero reference point of the zero index 133 and anydesirable desirable marks such as a mark to indicate the correctposition of the end socket on parallel wire bridge strand may also bemade at this time. The counting device 87 is either set to zero or itsreading is taken, and the exact position of the measuring wheel 67 withreference to the vernier index 137 is noted. The pulling device 53 isthen operated to pull the various wires 19 through the apparatus untilthe reading on the counter mechanism 87 and the vernier index readingindicate that the desired predetermined amount of wire has been passedthrough the measuring device 61. The movement of the wire through theapparatus is then interrupted and a section of the wire adjacent thezero index is again painted and a mark made at the zero reference point,plus whatever other marks may be desired. The operation of the pullingdevice is then resumed and may be continued until the counter and thevernier index reading indicate that another predetermined amount of wirehas passed through the measuring device 61 and another zero referencemark can be made. This operation is continued until the required numberof lengths of strand are fabricated and marked. The strand may besevered into precise predetermined lengths by cutting through the entirestrand with a suitable severing means such as an abrasive cutting wheelat the zero reference marks on wire 19a any time after the marked wireis incorporated into the finished strand either before reeling or afterreeling and unreeling.

Since a single wire can be more accurately measured by roller contactthan most if not all strands composed of a plurality of wires, themethod of the present invention of marking the one wire prior to itsincorporation into a strand and then cutting the completed strand intoprecise lengths according to the marks on the wire provides a superiormethod of measurement during continuous operation as well as extremeaccuracy. A single wire furthermore may be measured with great accuracywithout the application of the relatively high tension necessary tomeasure a strand accurately. If desired, two identical measuring devicesmay be used to measure two adjacent outside wires of the strand as acheck. Any possible discrepancy in the marks would indicate to theoperators of the strand making line that the particular length of strandshould be carefully checked by hand measurement. Such checking is veryrarely if ever necessary with the disclosed apparatus. however. 1

The described method and apparatus of measurement have a furtheradvantage in the making of strand in which it is desirable to mark thelocation of other structures upon the strand. For instance in the makingof parallel wire bridge suspension strand the future location of thesaddles over which the strand is supported on the bridge is also markedon the strand and as it is desirable not to have any wire splices in thearea of the saddle, by marking this area on the wires before the strandis compacted it is possible to remove any splices which may happen to belocated in the wires in these areas by cutting out this section of wireand pulling fresh wire forward from the appropriate swift to take itsplace. It will be understood that it would be very difficult to remove asplice once it is incorporated into a finished strand if measurement ofthe strand was delayed until the particular length of strand iscompleted.

Obviously the measuring device could also be used to directly measurenot only wire but other lineal material such as small twisted cable orrope. In the claims therefore the term wire is intended to encompasssuch structures.

lclaim:

1. In a method for making wire strand comprising drawing a plurality ofwires from a plurality of reel means and through die means to form aparallel wire strand the improvement facilitating the making of anaccurate length of strand comprising:

a. passing at least one but less than all of said plurality of wiresfrom said reel means to said die means through a roller measuring meansincorporating a counter;

b. taking a zero reading on said counter and making a first mark on thewire at a point having a predetermined position at the time of markingwith respect to a zero index associated with said measuring device;

c. drawing the wire through the device while simultaneously operatingsaid counter until the predetermined desired length of wire is countedoff; I

. making a second mark on the previously marked wire at a point having apredetermined position with respect to said zero index;

e. continuing to draw said plurality of wires through said die meansuntil the said second mark has passed therethrough; and

. subsequent to securing said wires together to prevent disruption ofsaid parallel wire strand severing said strand at locations adjacentsaid first and second marks on said marked wires.

2. The method of making wire strand according to claim 1 additionallycomprising counting the gross revolutions of said measuring wheel withsaid counter and the fine increments of revolution with a vernier indexmounted adjacent to the measuring wheel.

3. The method of making wire strand according to claim 1 wherein lessthan a majority of the wires of the strand are measured and additionallycomprising:

g. drawing said wires through said die means in parallel relation toeach other and afterward binding into a parallel wire strand by bindingat intervals with a suitable binding means.

passage of wire therearound in frictional relationship; first doubletension roll means positioned between said swift and said measuringwheel adapted for passage one to rotate only in a direction allowingpassage of said wire therebetween toward said compacting die means. 6. Amethod of making parallel wire strand comprising: a. providing aplurality of wires ofinde'finite length;

4. The method of making wire strand according to claim 3 5 b. measuringone of said plurality of'indefmite length wires additionally mPri iIIgZand marking thereon a length corresponding to a desired h. forming saidparallel wire strandinto a regular geometrilen h of arallel wire strand;

cal cross section and measuring ndm rking at least one c. arranging andbinding said plurality of wires together in Of the Wires which is to bea comer Wire in the completed the form of a parallel wire strand withsaid marked wire I'OS li n- 10 maintained as a surface wire on saidstrand; and PP for making Parallelwire Strand Comprising: d. severingsaid strand at the appropriate marks on said p y f 5Wifl5; marked wireto form a section of parallel wire strand of dlecompacung means; thedesired accurately predetermined length. a Pulling mefms P a ph fy ofwires f Said P P 7. A method for measuring and determining the length ofa rallty of SWlflS through said die compacting means in l 5 parallelwire Strand comprising. Parallel l'elanonshlpi 1 a. providing at leastone accurately premeasured standard d. means to facilitate binding saidwires in said parallel rela- Wire;

nonshlpl. b. combining said accurately measured standard wire with a ameasulfmg Wheel Poslt'oned between one of 831d plural" plurality ofunmeasured wires into a parallel wire strand;

ty of swifts and said die-compacting means adapted for and c.determining the length of the parallel wire strand with relation to thepremeasured standard wire. 8. A method of measuring parallel wire strandaccording to of said wires between said rollsof frictional contacttherewith; 25 means to urge rotation of the rolls of the first doubletenclaim 7 wherein at least two accurately premeasured standard wiresare marked with reference marks and additionally comprising:

sion roll means in a direction opposing passage of the wire;

d. prior to determining the length of said parallel wire strand withrelation to the premeasured standard wires checking h. second doubletension roll means between said measuring v wheel and said diecompacting means adapted for the accuracy of the measurement of thestandard wires by passage of said wire between said rolls in frictionalconcompanson prcmarked reference marks on tact therewith and twostandard wires.

i. means to allow the rolls of said second tension roll means

1. In a method for making wire strand comprising drawing a plurality ofwires from a plurality of reel means and through die means to form aparallel wire strand the improvement facilitating the making of anaccurate length of strand comprising: a. passing at least one but lessthan all of said plurality of wires from said reel means to said diemeans through a roller measUring means incorporating a counter; b.taking a zero reading on said counter and making a first mark on thewire at a point having a predetermined position at the time of markingwith respect to a zero index associated with said measuring device; c.drawing the wire through the device while simultaneously operating saidcounter until the predetermined desired length of wire is counted off;d. making a second mark on the previously marked wire at a point havinga predetermined position with respect to said zero index; e. continuingto draw said plurality of wires through said die means until the saidsecond mark has passed therethrough; and f. subsequent to securing saidwires together to prevent disruption of said parallel wire strandsevering said strand at locations adjacent said first and second markson said marked wires.
 2. The method of making wire strand according toclaim 1 additionally comprising counting the gross revolutions of saidmeasuring wheel with said counter and the fine increments of revolutionwith a vernier index mounted adjacent to the measuring wheel.
 3. Themethod of making wire strand according to claim 1 wherein less than amajority of the wires of the strand are measured and additionallycomprising: g. drawing said wires through said die means in parallelrelation to each other and afterward binding into a parallel wire strandby binding at intervals with a suitable binding means.
 4. The method ofmaking wire strand according to claim 3 additionally comprising: h.forming said parallel wire strand into a regular geometrical crosssection and measuring and marking at least one of the wires which is tobe a corner wire in the completed cross section.
 5. Apparatus for makingparallel wire strand comprising: a. a plurality of swifts; b.die-compacting means; c. a pulling means to pull a plurality of wiresfrom said plurality of swifts through said die compacting means inparallel relationship; d. means to facilitate binding said wires in saidparallel relationship; e. a measuring wheel positioned between one ofsaid plurality of swifts and said die-compacting means adapted forpassage of wire therearound in frictional relationship; f. first doubletension roll means positioned between said swift and said measuringwheel adapted for passage one of said wires between said rolls offrictional contact therewith; g. means to urge rotation of the rolls ofthe first double tension roll means in a direction opposing passage ofthe wire; h. second double tension roll means between said measuringwheel and said die-compacting means adapted for passage of said wirebetween said rolls in frictional contact therewith; and i. means toallow the rolls of said second tension roll means to rotate only in adirection allowing passage of said wire therebetween toward saidcompacting die means.
 6. A method of making parallel wire strandcomprising: a. providing a plurality of wires of indefinite length; b.measuring one of said plurality of indefinite length wires and markingthereon a length corresponding to a desired length of parallel wirestrand; c. arranging and binding said plurality of wires together in theform of a parallel wire strand with said marked wire maintained as asurface wire on said strand; and d. severing said strand at theappropriate marks on said marked wire to form a section of parallel wirestrand of the desired accurately predetermined length.
 7. A method formeasuring and determining the length of a parallel wire strandcomprising: a. providing at least one accurately premeasured standardwire; b. combining said accurately measured standard wire with aplurality of unmeasured wires into a parallel wire strand; and c.determining the length of the parallel wire strand with relation to thepremeasured standard wire.
 8. A method of measuring parallel wire strandaccording to claim 7 wherein at least two aCcurately premeasuredstandard wires are marked with reference marks and additionallycomprising: d. prior to determining the length of said parallel wirestrand with relation to the premeasured standard wires checking theaccuracy of the measurement of the standard wires by comparison of thepremarked reference marks on said two standard wires.